less maintenance and better performance in sugar and ... · pdf fileless maintenance and...

News15

Less Maintenance and Better Performancein Sugar and Ethanol ProductionThe more critical a pH measurement is, the more accurate and reliable

the pH measurement system has to be. METTLER TOLEDO offers intelligent,

high performance sensors with advanced diagnostic capabilities, that

predict their own maintenance requirement – the perfect solution for a

Brazilian group trying to reduce maintenance costs.

Brazilian sugar producerOur customer is one of the biggest sugar

and ethanol production groups in Brazil.

It has been producing sugar for almost

one century and ethanol for over three

decades. At peak production it produces

15,000 sacks of sugar per season.

ApplicationsTwo of the most critical applications in

sugar and ethanol production from cane,

are liming and fermentation.

In the first process, milk of lime (CaO

particles suspended in water) is pumped

into raw sugar juice for three reasons:

n to neutralize acids in the cane, there-

by preventing the sucrose from

turning into starch or other forms of

sugar

n to precipitate the organic acids into

salts for subsequent removal

n to keep foreign matter in suspension

until it can be removed by filtration.

pH measurement is used as an indicator

of the right amount of CaO to be added.

The measurement is challenging as the

lime tends to adhere to the electrode,

which therefore requires regular clean-

ing.

Anaerobic fermentation of the cane juice

produces ethanol, which is later separated

during a distillation process. Yeasts sup-

porting fermentation require tightly

controlled temperature and pH conditions

for maximum conversion of the natural

sugars into alcohol. For best results, the

pH value of the juice must be held within

INGOLD Leading Process Analytics

Sugar Starch & YeastPerspectives in Liquid Process Analytics

2 METTLER TOLEDO Sugar News 15

Publisher / Production Mettler-Toledo AG

Process Analytics

Im Hackacker 15

CH-8902 Urdorf

Switzerland

IllustrationsMettler-Toledo AG

Marlee, Margouillat, Stormur, Imdan

| Dreamstime.com

Subject to technical changes.

© Mettler-Toledo AG 12/09

Printed in Switzerland.

3.0 – 3.5 during the fermentation pro-

cess.

Our customer is already a user of

METTLER TOLEDO pH systems in other

areas of the mill. Though very satisfied

with the equipment, with the new systems

the customer wanted a lower maintenance

burden and was looking for a solution to

the problem of signal degradation due to

the humid process conditions.

ISM delivers the main require-mentsTwo METTLER TOLEDO systems were

installed. For the liming process an

InPro 4800 i pH electrode was chosen for

its resistance to high temperatures and

alkali solutions. For the fermentation

process the InPro 3250 i was selected due

to its excellent measurement performance.

The M400 was installed as the transmitter

for both systems.

The electrodes were chosen not just for

their suitability to the processes. The “i”

suffix indicates that they are part of

METTLER TOLEDO’s Intelligent Sensor

Management (ISM) range of sensors, and

it is the ISM features that provide the vital

requirements the customer requested.

Microchips in the head of the electrodes

monitor the sensors for signs of stress or

degradation and transfer the information

to the transmitters. The advanced diag-

nostics features of ISM systems interpret

the sensor data to inform the user when

electrode cleaning or calibration is re-

quired. Thus maintenance can take place

only when it is needed, rather than wait-

ing until measurement performance from

the sensor is reduced, or conducting regu-

lar maintenance when it may not be

necessary.

Stay one step ahead of maintenance with ISM

Intelligent Sensor Maintenance reduces the installation, main-tenance and calibration effort for METTLER TOLEDO’s digital sensors to a minimum. This considerable improves process reliability, productivity and sys-tem availability.

Find out how ISM can help you, at:

Best Practice

www.mt.com/ISM

www.mt.com/InPro3250i

In an ISM system, communication be-

tween sensor and transmitter is via a

digital signal. Low-impedance digital

signals are unaffected by humid condi-

tions, even over long cable lengths, giving

the customer robust data at all times.

Satisfied customerThe combination of reliable signal, pre-

dictive maintenance and dependable,

accurate pH measurement is exactly what

our customer was looking for. Such is

their satisfaction that they are now con-

sidering upgrading their other METTLER

TOLEDO installations with ISM equip-

ment.

Discover more at:

Transmitter M400

pH electrodeInPro 3250 i

Transmitter M420

METTLER TOLEDO Sugar News 15 3

Cond

uctiv

ity T

rans

mitt

ers

M420 2-wire transmitter, a reliable solution for hazardous area applications Designed for hazardous area operation,

the M420 2-wire transmitter is the perfect

solution for advanced process control. Key

features include the IP 67 rated enclosure

and options for additional functions e.g.

for extended logbook or a second output

signal. As the 2-wire transmitter with its 4

- 20 mA output signal provides HART

communication as standard, the M420

represents a future-proof investment for

integration into your process control sys-

tem.

Trouble-free Conductivity MeasurementA New Team of 2- and 4-Wire TransmittersMonitoring conductivity is an excellent way of ensuring product quality,

reducing product loss and optimizing processes. The latest editions to

our conductivity transmitter line feature Intelligent Sensor Management

(ISM) for even greater productivity.

Important measurementConductivity measurement with 2-e or 4-e

sensors is common for monitoring water

quality during water purification. For

concentration determination through

chemical processes, very often an induc-

tive conductivity measuring approach is

chosen.

M400 4-wire transmitter, a versatile solution for standard applications Thanks to its multi-parameter capabili-

ties, universal power supply, number of

current output signals and relays, the

M400 4-wire transmitter is a particularly

versatile instrument. The Intelligent

Sensor Management (ISM) Plug and

Measure function and Quick Setup routine

enables quick and simple commissioning;

while the display provides measurement

values from two sensors, and alarms for

out-of-spec conditions, plus warnings of

potential sensor failure.

ISM – the leading sensor technologyMETTLER TOLEDO’s new transmitters all

feature ISM technology for better process

and maintenance control of measurement

points, without compromising process

reliability. The mixed mode input feature

of the transmitters means that digital ISM

sensors or traditional analog sensors can

both be connected. The transmitters can

be used in combination with 2- or 4-elec-

trode sensors as well as inductive

conductivity sensors. The large backlit

display with its clearly structured menus

ensures intuitive and easy operation.

The METTLER TOLEDO solution METTLER TOLEDO is a total solution

provider with many years’ experience in

conductivity measurement. Our portfolio

covers various transmitter lines, analog

and innovative ISM technology digital

sensors, as well as housings for a wide

range of applications.

Discover more at:

www.mt.com/M400www.mt.com/M420

Transmitter M400


Yeas

t Fer

men

tatio

n

n DO measurement system:

M400 transmitter in combination with

DO sensor InPro 6850 i.

The digital pH electrode InPro 3100 i fea-

tures special design elements that

effectively prevent clogging and fouling.

This makes it ideal for use in yeast fer-

mentation as contamination by bacteria

represents the greatest risk factor during

all stages of production. It is therefore

essential to maintain a slightly acidic pH

value and to sterilize the measuring

equipment and culture medium (molas-

ses) in order to prevent any bacterial

growth.

The same requirements can also be fully

met by the DO sensor InPro 6850 i, which

combines hygienic design (sterilizable or

autoclavable and hygienically polished

surface finish) with exceptional measure-

ment accuracy.

The use of these two measurement systems

from METTLER TOLEDO guarantees

accuracy and dependability of the mea-

surement values, as well as full process

reliability.

ResultsOver many tests of the process parameters,

precise pH and DO measurement values

were established. This enabled the consid-

erable improvement in production

efficiency and product quality that the

production engineers were looking for.

The tests showed that for optimal process

results, pH values should lie between 4.5

and 5 during preparation of the molasses,

and between 5 and 8 during the different

fermentation stages. It was also possible to

determine the precise amount of dissolved

oxygen required in relation to the amount

of substrate added during the course of the

reaction phase. Achieving this balance

would prevent formation of ethanol (and

other volatile dissolved substances) during

the transition from aerobic to anaerobic

fermentation.

Scale upThe pilot phase results made it possible to

extrapolate the values required for direct

application in large volume production

fermenters (10,000 liters and 15,000 liters).

Additional pH and DO measurement sys-

tems were purchased from METTLER

TOLEDO which are now being used to

monitor the different fermentation stages

for smooth running of full-scale produc-

tion.

To improve product yield and quality at

your facility, go to:

How Does Measuring pH and DO In-lineImprove Yeast Production?In-line measurement of pH and dissolved oxygen (DO) values is an

effective way of monitoring primary and secondary yeast fermentation,

with the added bonus of improving yield and quality.

Production of baker’s yeastA French group specializing in the pro-

duction of baker’s yeast was convinced

that they could achieve significantly im-

proved product yield and quality if they

could more precisely control the different

fermentation processes. In particular they

wanted to test the influence of pH and DO,

and to this end set up a 100 liter pilot

fermenter with the pure yeast strain

Saccharomyces cerevisiae together with

molasses (a by-product of sugar rich in

saccharose).

Measurement of pH and dissolved oxygenProduction engineers at the factory knew

that to optimize fermentation they would

need dependable, continuous and real-

time pH and DO measurement values.

This would allow rapid intervention in the

fermentation process and timely adjust-

ment of external parameters in the event

of out-of-spec conditions. They asked

METTLER TOLEDO for measurement so-

lutions that would best meet their

requirements.

The solutions provided by METTLER

TOLEDO consisted of:

n pH measurement system:

M400 transmitter, InPro 3100 i pH

electrode and static housing InFit 761

CIP for insertion of the electrode into

the fermenter.

www.mt.com/pro-pHwww.mt.com/DO


InPro 6850 i DO sensorn Low maintenance and long lifetime

n Long lasting membranes

n Easy-to-replace membrane body

n ISM technology for easier installation,

maintenance and calibration

n Quick-disconnect interior body

n In situ fully autoclavable or steriliz-

able

InPro 3100 i pH electroden Low maintenance and long lifetime

n Gel electrolyte – no refilling required

n Resists fouling and clogging – less

cleaning required

n ISM technology for easier installation,

maintenance and calibration

n In situ fully autoclavable or steriliz-

able

n Watertight process connector for easy

connection

Be clever – with Intelligent Sensor Management (ISM)

Thanks to ISM technology, digi-tal sensors are able to monitor themselves in real time for possible defects, providing you with status information to pro-actively identify maintenance requirements.

Discover more at:

Best Practice

www.mt.com/ISM


Cabl

eles

s So

lutio

n

tion. It is also the perfect answer for

remote monitoring tasks.

The W100 supports ISM sensors for pH, DO

as well as 4-E conductivity, which are

compatible with the advanced transmitter

line M400 or the value transmitter line

M300.

Additional benefits of the cableless solu-

tion include the long battery lifetime of up

to 6 months, and the communication

range of up to 150 meters.

Discover more at:

Tricky Sensor Installation Point?Go Cableless!Proper wiring between sensor and transmitter can be very costly, especially

in locations with limited access or where moving parts can be a hazard.

The cableless solution W100 gives you the option to solve expensive and

challenging installation conditions at a very reasonable cost.

No more cablesWith the W100, METTLER TOLEDO offers

an innovative solution for cost-intensive

measurement point installations. Based

on reliable and industry-proven wireless

technology (according to IEEE802.15.4),

the W100 replaces the cable between

METTLER TOLEDO Intelligent Sensor

Management (ISM) sensors and the

transmitter, and provides bi-directional

digital data transfer with full calibration

and diagnostics functionality.

Real-time monitoring of the measurement

value as well as auto-recognition of the

sensor is ensured. Additionally, the W100

convinces with its very simple one button

operation, which is also the basis for the

easy pairing between transmitter and

sensor. Thanks to the LED display, the

state of the W100 can be recognized at a

glance. Installation at existing ISM mea-

suring points is simple as there is no need

to change any transmitter settings.

For many applicationsSince there is no cable to be laid, the sys-

tem offers great advantages in applications

where high installation costs due to

physical barriers or contamination risks,

exist. Also, in applications where the

measuring point is needed only temporar-

ily, where the installation of the sensor

has to be changed several times, or where

the sensor is mounted on a moving part,

the W100 is a highly cost-efficient solu-

Stay one step ahead of maintenance with ISM

A METTLER TOLEDO ISM mea-suring system with the W100 will not just save on installation costs; ISM also reduces the maintenance and calibration effort to a mimimum. This con-siderably improves process reliability, productivity and sys-tem availability.

Find out how ISM can help you, at:

Best Practice

www.mt.com/ISM

www.mt.com/W100


O 2 G

as M

easu

rem

ent

This technology, with a proven industrial

track record due to its simplicity and rug-

gedness, is ideally suited for the in-situ

measurement of gaseous oxygen.

METTLER TOLEDO offers a comprehen-

sive range of amperometric systems with

sensors for wide application coverage, re-

tractable housings for sensor extraction

without process interruption, and trans-

mitters for signal conversion and

connection to process control systems

using HART, FOUNDATION fieldbus or

PROFIBUS. Naturally, the complete mea-

surement system is available with ATEX

Zone 0 / FM Class 1 Div 1 approval if re-

quired.

Amperometric sensors can be maintained

in two minutes, with minimum impact on

your running process. All that is required

is to replace the membrane body and fill

it with fresh electrolyte solution.

Subsequent calibration can be performed

on site using air as a calibration gas.

Measure Oxygen Where it Really MattersDirectly in Your ProcessPerformance of gaseous oxygen measurement is now redefined with

METTLER TOLEDO’s amperometric systems. They not only allow reliable

and stable measurement, they are inexpensive to maintain and, what’s

more, do not require any gas sampling system.

Unwanted oxygenOxygen levels in industrial processes are

heavily controlled to contain the risk of

explosion of flammable liquids and dusts,

as well as to protect products against oxi-

dation. Not only is oxygen monitoring a

critical issue in transport systems, storage

tanks or centrifuges, it can also nega-

tively affect the yield of a chemical

reaction in a vessel.

Many solutions – which is best?When selecting a vendor for a measure-

ment system, technologies and solutions

abound, but in many cases a trade-off

exists between sufficient performance and

reliability, and reasonable maintenance

effort and system availability. In order to

function correctly, paramagnetic systems

need to protect the measurement cell from

heat, moisture and / or corrosive gases.

However, the more instruments there are

between the process and the sensor, the

longer the response time will be and the

higher the probability of system failure.

Amperometric: simple and reliableLooking at the field of dissolved oxygen

measurement however, membrane-based

amperometric sensors using the Clark

principle offer an alternative. For decades

they have demonstrated optimum perfor-

mance in a wide range of applications

ranging from fermentation processes in

breweries, in biopharmaceutical indus-

tries or in chemical process applications.

www.mt.com/O2-gas

Intelligent sensors for smart processesAll amperometric sensors from METTLER

TOLEDO are available in digital versions

equipped with Intelligent Sensor

Management (ISM) technology. With the

Plug and Measure feature, pre-calibrated

sensors can be immediately used in the

process, minimizing the time necessary

for maintenance and without the need for

specialist know-how. Additionally, ISM

sensors have built-in self-diagnostic

abilities in order to detect early signs of

failure such as low electrolyte levels, and

alert users before measurement quality or

process availability is impacted.

If you want to save costs on O2 measure-

ment at your facility, go to:

www.mt.com/ISM

Dissolved oxygen sensor InPro 6850 i

F O2

Paramagnetic system

N2 in

METTLER TOLEDO solution

The sample path through a The METTLER TOLEDO solution paramagentic system is long and slow. measures directly in the vessel – immediately.


Com

preh

ensi

ve W

ebsi

te The Information you Want is at www.mt.com/pro

The METTLER TOLEDO Process Analytics web-site contains a vast amount of up-to-date information on all our products and services.

Content is localized for your country and tailored to suit your selections.

Simple layout allows you to quickly find the infor-mation and features you are looking for.

n Learn about our most recent product develop- ments

n Register for free webinars

n Request further information on products and services

n Obtain a quote quickly and easily

n Download our latest white papers

n Read case studies relevant to your industry

n Access buffer and electrolyte solution certificates

n and more...

A typical Product page: with Features

and Benefits and quick access to rele-

vant application information,

related products and downloads


The Information you Want is at www.mt.com/pro

Search by Product or by Application n Read the latest product news

n Access our Newsletter archive

n Find out when our next Trade

Show or Exhibition is in your

area

n Register for free webinars

presented by our industry

experts

n Download our White PapersApplication pages help guide you to the

products that are right for your processes


Plug and Measure

Inte

lligen

t Sen

sor M

anag

emen

t Intelligent Sensor Management Reduces Life Cycle Costs and Improves Process Safety

Intelligent Sensor Management (ISM)ISM reduces the installation, maintenance and calibration effort for METTLER TOLEDO’s digital sensors to a minimum. This considerably im-proves process reliability, productivity and system availability.

Reliable installationDigital communication between sensor and transmitter means signal is always reliable and unaffected by moisture.

Intelligence – starts in the headISM sensors are equipped with integrated elec-tronics in the sensor head that store all relevant sensor parameters and includes algorithms for enhanced sensor diagnostics.

Predictive maintenanceIntelligent diagnostics information is calculated and displayed on the sensor's transmitter and tells you if the sensor needs maintenance or replacement – no more downtimes due to sen-sor failure!

System integrationKey ISM parameters can be fully integrated in a process control system via PROFIBUS® PA or FOUNDATION Fieldbus™.

■ Sensors are immediately recognized when connected to the transmitter – eliminating difficult configuration procedures.

■ Operational availability of measurement point within seconds.

■ Wireless module available for transmission from sen-sor to transmitter – no need for costly cable installation.

■ Sensors can be pre-calibrated in the lab and stored for later use, saving time and increasing operational avail-ability.

METTLER TOLEDO’s ISM product range includes…

… a wide range of sensors for … advanced single- and multi-channel transmitters … software applications ■ pH ■ 4-wire ■ iSense Asset Suite ■ dissolved and gaseous O2 ■ 2-wire ■ pH data logger ■ conductivity ■ wireless module ■ turbidity


Intelligent Sensor Management Reduces Life Cycle Costs and Improves Process Safety

Diagnostics Maximum Performance

■ Any sensor maintenance requirement is recognized at an early stage, reducing downtimes and minimizing plant operation costs.

■ Dynamic Lifetime Indicator estimates in real time the remaining lifetime of the sensor.

■ CIP / SIP cycles counted automatically.

■ Sensor spider diagram for fast troubleshooting.

■ iSense Asset Suite software offers you a unique means of optimizing the performance of ISM sensors for en-hanced reliability and process safety.

■ Key Performance Table enables you to evaluate the condition of an ISM sensor at a glance, without the need of a transmitter.

■ Documentation of every calibration as well as the entire sensor history – documentation requirements to regu-latory standards are easily met.

METTLER TOLEDO’s ISM product range includes…

… a wide range of sensors for … advanced single- and multi-channel transmitters … software applications ■ pH ■ 4-wire ■ iSense Asset Suite ■ dissolved and gaseous O2 ■ 2-wire ■ pH data logger ■ conductivity ■ wireless module ■ turbidity

Intelligence starts in the head

www.mt.com / ISM

Visit for more informationwww.mt.com/pro

Accurate Phase Separation with Intelligent Conductivity SensorsProduct losses will be minimized and your yield maximized if you use a faster and more accurate phase separation monitoring solution. The new conductivity sensors from METTLER TOLEDO measure more quickly and more precisely – that means better phase separation control, increased yield and lower costs. Further, with built-in Intelligent Sensor Management (ISM) tech-nology, sensors carry their own up-to-date status data which is automatically uploaded to the transmitter, thus allowing fast and error-free start up.

When precise measurement and easy handling are important, think ISM conductivity sensors from METTLER TOLEDO.

www.mt.com/Cond

Get in-line with METTLER TOLEDO

Mettler-Toledo Ind. E Com. Ltda.Divisão ProcessoAlameda Araguaia, 451Alphaville - Barueri - SP - 06455-000Fone: (11) 4166-7444 (vendas) / 4166-7400 (pabx)Fax: (11) 4166-7401E-mail: [email protected]

Mettler-Toledo S.p.A. Via Vialba, 42 20096 Novate Milanese (MI) Phone: +39 02 333 321 Fax: +39 02 356 29 73 E-Mail: [email protected]

Mettler-Toledo AGProcess AnalyticsIm Hackacker 15, CH-8902 Urdorf, Switzerland

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